I need the advice of experts to fix a comedy of errors: One Stupid Mistake
After Another. I'm getting much contradictory advice and need you experts,
especially those who know aluminum welding, machining, etc. Please include
me in P-MAIL as I'm not able to be on the list.

Due to fixing broken studs holding on the alternator bracket to the
crankcase on a 1984 1.9L (and the installation of a Heli-coil), a hole was
accidently drilled all the way through the crankcase into the water jacket.
Despite a slug of sealant and new longer studs, it won't hold water. The
aluminum block heats and expands faster than the metal studs and a vast
water leak results through the resulting gap around the threads. No amount
of Permatex sealant is working.

The fix may have to be temporary. I'm leaving in a week to take a job in
Alaska and a rebuild/overhaul is out of the question due to time/money/place
to work. Later, sometime this summer, a more permanent fix (including engine
overhaul) might be done. But this fix must work! Can't be broken down on the
Alaska Highway at -10F 200 miles from a shop.

Suggestion 1: (the quickie fixie)
"Weld" in a new stud with J-B Weld, which should seal the hole. My concern
is that the J-B Weld won't expand with the aluminum and a gap will form
around the threads resulting in more leaking. Does anyone know? Obviously
another concern is getting the stud out someday if it ever breaks again...

Suggestion 2:  (the proper fix)
Pull engine, weld shut hole, drill and tap new hole. My concerns:

a) Can weld be done without disassembling crankcase? I assume heads must be
pulled to protect them from heat of welding, but what else would I have to
take apart? Pulling the engine out and taking it to a machinist is about the
extent of what I can do now with my work space and time. Taking the
crankcase apart just opens up (sorry) too many potential problems.

b) can a new hole be drilled in the exact same spot the old hole is welded
shut? Just checking...

Thanks SO much! You folks always save my ass. It'd be nicer to ride the ass
to Alaska than push it...

Steve
1984 Westy
Mount Vernon, WA
360-428-7018

_________________________________________________________________
Get your FREE download of MSN Explorer at http://explorer.msn.com